Hinduja Group An Overview

11

Hinduja Group – An Overview

• Founded in 1914• Trans-national conglomerate• Presence in 100 countries

with more than 70,000employees

• Sales revenue - $25 billion(~ Rs. 170,000 Crore)

GUIDING PRINCIPLES:

• Work to Give

• Word is a Bond

• Act Local Think Global

• Partnership for Growth

• Advance Fearlessly

Banking & Finance

Chemical/Lubes

PowerInformation Technology

Real EstateMedia HealthcareProject

DevelopmentTrading

Automotive

http://www.hindujagroup.com/default.html

22

Truck

• Long Haul

• Mining & Construction

• Distribution trucks

Bus• City Bus• Suburban Bus• Inter City Bus• School & Special Bus

Light Vehicle

• Dost• Partner• MiTR• BADA Dost

Specialty Vehicle

• Bulker• Fire brigade trucks

Power Solution

• Generator sets• Marine Application• Harvester Combine

Ashok Leyland - Product Portfolio

• Over 700,000 trucks keep the wheels of Indian economy moving

• Every year Ashok Leyland buses transport over 26 billion people

(equal to 3.5 times of world’s population)

33

Hosur Unit II plant (ALH2)

•Vehicle Manufacturing plant located on Bengaluru- Chennai Highway

•Plant Capacity : 121,000 trucks/annum (M&HCV:56,000 and LCV:65,000)

•ALH2 Sales Revenue :$ 1251 Mn(FY19)

(31.3 % of Ashok Leyland turnover)

Low investment plant with significant contribution to company’s turnover

*Conversion ratio 1 $ : INR 73

44

Self DeclarationHand Washing

Vehicle disinfection

Doctor verification Mask Distribution

Aarogya Setu App Checking Thermal Scanning

Social Distancingat Canteen

Office fumigation

Entry at Gate

We have resumed our operations with effect from 11th May 2020 after obtaining appropriate approval from District Collector, Krishnagirivide his letter dated 5th May 2020 with guidelines to adhere the conditions as prescribed by the Ministry of Home Affairs and the StateGovernment.

2.Impact of COVID-19

55

3.Specific Energy Consumption…

2,709

2,020

1,719

1,379

1,306

1,201

1,068

1,1771,205

1,2451,147 1,239

642610

646 647 638

562 520 512 501

2500

2500

2000

1429

1290

1100

1100

1050 1050 11001080

1108745

704

610 610 610

581 523 510 510

0

500

1000

1500

2000

2500

3000

FY01 FY02 FY03 FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21

EN

ER

GY

/ H

EC

U (

kW

h)

ENERGY PER HECU -TREND

Actual kWh/HECU Target (kWh / HECU)

Better

74% of reduction YoY

Long trend

66

3.Specific Energy Consumption…

Last 3 years trend

520 512 501

523 510 510

200

300

400

500

600

700

800

900

1,000

2018-19 2019-20 2020-21

EN

ER

GY

/ H

EC

U (

kW

h)

ENERGY PER HECU -TREND

Actual kWh/HECU Target (kWh / HECU)

Better

13% of reduction YoY

1.3

1.25 1.24

1.32

1.29

1.26

1.2

1.22

1.24

1.26

1.28

1.3

1.32

1.34

2018-19 2019-20 2020-21

Ther

mal

En

ergy

in G

J /

HEC

U

Axis Title

Thermal Energy / HECU Trend

Actual GJ/HECU Target GJ/HECU

Better

77

4.Bench marking

Internal

➢ Benchmark of same unit which won “1st Place in National Energy Conservation Competition-

2014” in the Automobile Sector conducted by BEE

➢ Process differs from plant to

plant & local conditions

➢ Difference in outsourcing level

➢ Product of different

specifications

➢ Various levels of system buying

External / Global

1221 12501198

940999

1289

1148

15001463

520 512 501

0

200

400

600

800

1000

1200

1400

1600

2018-19 2019-20 2020-21

kWh / HECU

PantNagar Unit Hosur unit-1 Ennore Unit Hosur Unit-2

88

5. Energy Saving projects implemented in last three years

Sl.No

Project descriptionPictorial

representation

Annual Electrical savings Annual Thermal savings

Investment in Rs. MillionKwh

Cost Savings in Rs.

Million

Qty

Cost Savings in Rs.

Million

1

One of the conventional Reciprocating compressor (which is having 200kw motor for the generation of 1250CFM of compressed) air replaced with Energy Efficient Screw compressor of 160kw motor.The heat generated in the screw compressor recovered and used to pre-heat the water for the hot water generating process.

950400 6.17 78 kL 4.68 60

2

All the shop floor lightings, of 150Watts HPSV high bay lamps converted into 118Watts LED lightings all over the plant.

409500 3.152 NA NA 27.6

Major ENCON project implemented in FY19

99


Sl.No

Project descriptionPictorial

representation

Annual Electrical savings Annual Thermal savings

Investment in Rs. MillionKwh

Cost Savings in Rs.

Million

Qty

Cost Savings in Rs.

Million

3

Ambient temperature reduction initiatives inside compressor room ✓ 1.Layot modification of heat

generating equipment’s inside the compressor house to avoid heat radiation from neighbor equipment

✓ 2.Extended ventilation for the compressor house for better cross ventilation

✓ 3.Exclusive ducting’s for the compressors to vent out the heat from the compressor house

✓ 4.Introduction of turbo ventilators in the roof of the compressor house

186200 1.44 NA NA 0.2


1010


Sl.No

Project description Pictorial representation

Annual Electricalsavings

Annual Thermal savings

Investment in Rs. Million

Kwh

Cost Savings in Rs.

Million

QtyCost

Savings in Rs. Million

1Energy efficient compressors installation - 1450 CFM - 1 no

576000 4.435 NA NA 0.18

2 Energy efficient Drier installation 65520 0.505 NA NA 0.42

3Replacement of ceiling fans (80 watts) with BLDC ceiling fans (40 watts) - 145 nosas 1st Phase – SUPERFAN

21700 0.16 NA NA 0.55


1111

Sl.No





Kwh

Cost Savings in Rs.

Million

Qty

Cost Savings in Rs.

Million

4

Automatic sprinklers in place of tractor driven supply of water for greenerymaintenance

NA NA96000

Lit67.21 0.26

5

Replacement of conventional centrifugal pumps of 7.5 replace with Energy Efficient “GRUNDFOS” make pumps of 5.5kW -2 nos at OHT water lifting

10440 0.08 NA NA 1.2

6LED lightings : RSO finished truck stock lights, Peripheral Street/Lawn lightings

27240 0.209 NA NA 0.89



1212


Sl.No





Kwh

Cost Savings in Rs.

Million

QtyCost

Savings in Rs. Million

1BLDC Motor Driven Blowers introduction of cabin paint shop.

1382400 10.71 NA NA 0

2Propane Introduction instead of Diesel for paint shop burner

NA NA 3745 kL 218.04 32

3LPG introduction for Boiler Operations at Canteen & ETP process (8000Lits / Month)

NA NA 96kL 6.72 8


1313

6. Innovative Projects implemented

✓ Introduction of “BLDC” motor driven Air Handling Units for Paint Shop

✓ Intelligent Water Management system

✓ Integrated RBT in assembly line…. first time in commercial vehicle industry

1414


✓ Integrated RBT in assembly line…. EOL (End Of Line) testing Process

Past Process:

Manual Wheel Alignment

Roller Test Bench

Brake TestABS Test

Off Track from Assy Conveyor

800mts by road

12Mins 15Mins

6Mins4Mins

Avg.Cycle time :35min/Vehicle

Diesel : 1.8 Liters/ Vehicle

SALES

7Mins

1515


✓ Integrated RBT in assembly line…. EOL (End Of Line) testing Process Idea & Objective:➢ Integrated Automated Contactless test Booth for Wheel alignment & Roller Brake test-

M/s.DURR, German➢ To be positioned next to off-track stage of Conveyor➢ Cycle time/ Tact Time to be inline with Conveyor (7 Mins/ Vehicle)Current Process:

Off Track from Assy Conveyor

Integrated EOL

Avg.Cycle time :6.5min/Vehicle

Diesel : 0.4 Liters/ Vehicle

7Mins

7Mins

1616


✓ Integrated RBT in assembly line…. EOL (End Of Line) testing Process

1. Productivity improvement by 74%

2. Energy Conservation reduction by 1714285 units/ Annum

✓ Energy cost saving : Rs.12.0 Millions

3. Diesel Conservation upto : 28658 Lits / Annum

✓ Diesel cost Saving : Rs.20.06 Millions

4. Set benchmark of “End of Line Testing Process” cycle time matched with “Assembly Conveyor Cycle

Time”

5. Horizontal deployment in “DOST” assembly line in FY21

6. Elimination of “Vehicle Test Shop” process

✓ Benefits

Special Note:1. 1st of its kind in a commercial vehicle industry to Completed EOL tests at end

of conveyor2. 1st of its kind to meet cycle time inline with conveyer cycle time.

1717

7. Utilization of Renewable Energy Sources

Roof Top SOLAR (inside plant) Energy contribution FY21 : 6.75%

Wind Mill Energy contribution : FY21 : 29%

Captive SOLAR ( outside plant)Energy contribution FY21 : 31.25%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

FY 19 FY 20 FY 21

Power Mix

SOLAR WM IEX GCP DG TNEB

67% Green Energy

1818

8. Waste Utilization & Management

Ashokleyland, Unit-2,HosurPre-processor

M/s.GGEPIL,RanipetFuel for cement Kiln

M/s.Ultratech Cements,Karur

267

196

76.27

0

50

100

150

200

250

300

FY19 FY20 FY21

Qty

. in

MT

Year Wise paint sludge disposal as Fuel

Qty. disposed in MT

Industrial Waste Management

1919

8. Waste Utilization & Management

Domestic Waste Management

Canteen wastages like food, egg shells,vegetable peels etc being converted as manure in Organic Waste Composter-500Kg/Day Capacity

2020

9. GHG Inventorisation

9450

7293 72626631

59395308

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

Ton

nes

of

CO

2e

Scope 1 emissions : Emissions from fossil fuel usage within the premises

12828

4694

1230123

0

2000

4000

6000

8000

10000

12000

14000

Base line FY 18 Scope 2 - FY21 Power mixbalancing - Solar

& Wind FY 22

Green Energy inleft over slots -

FY 23

Ton

ne

s o

f C

O2

e

Scope 2 emissions : Emissions from to fossil fuel usage due to (TNEB, IEX, CPP power usage)

22278

11987

6971 6340 5649 5618 5048

1584477

-155

-5000

0

5000

10000

15000

20000

25000

Scope 1 +2emissions Base

line

Scope 1 +2emissions FY 21

Existing carbonsink - 1.32 Lakh

trees

100 % propanein paint shop FY

22

DG avoidanceusing 110 KV

Waste heatrecovery

projects FY 22

Carbon sinkwith 15 K trees

Power mixbalancing -

Solar & WindFY 22

Green Energy inleft over slots -

FY 23

Solar basedheating systemfor Oven FY 25

Ton

nes

of

CO

2e

Scope 1 +2 emissions (6k +6k each from M& HCV and LCV)

Carbon negative with – 155 t CO2e -FY 25

2121

10. Green Supply Management

442

402380

365342 348 340

325

231263 252

275

0

50

100

150

200

250

300

350

400

450

500

FY 17 FY 18 FY 19 FY 20

Total supplier ISO9000 ISO14001

❖Significant Initiatives :

• Awareness Creation to Supply Chain Partners ( 63 Supplier Gemba’s Started at Organisation Level )

• Adoption of vendors for Gemba Concepts Implementation

• Procurement of Energy efficient ,Water efficient Equipment

• Incentivize the Vendors with Recyclable pallets

Green Purchase

•Adoption to No. of Parts/Suppliers

•Greening the Supply Chain

2222

11. Team work, Employee Involvement & Monitoring

Online Monitoring... Capturing in SAP

Daily•Aggregate-wise daily reports to GEMBA leaders

Weekly

•Power cost analysis with respective process owners

•Corrective actions planning

Monthly•Gap analysis review by Unit Head

Plant Head•Inter unit review by VP-Hosur units

9.5)Conducting various competitions like Poster making,Photography

contest ,ENCON Ideas & Awarding Best ENCON Projects through Kaizens

2323

14.Other relevant Information.

Madhakondapalli Lake rejuvenation : Volunteers from ALH2 participated in CSR’s initiative of lake rejuvenation. Aspiring to get 250 Dried Borewells recharged irrigation for 4,000 acres of 3 adjacent villages in FY22

2424


Sapling donation to MYRADA (Mysore Resettlement and Development Agency)❖ MYRADA is an NGO that has had extensive experience in incubating, developing and

managing sustainable growth in south India

2525


Awareness to public at Bodichipallivillage near Kelamangalam,TN

Spreading awareness to families, students and Visitors

❖ On TN Govt’s directive Ban on “use of one time use and throwaway plastics” following initiatives implemented progressively

❖ On 27/09/19 a knowledge sharing session on “Awareness on Harmful effects of plastic” was conducted by MR-H2 to the staffs of “Central Silk Board Authority of India”-Hosur

2626


Awareness to public at Bodichipallivillage near Kelamangalam,TN

Spreading awareness to families, students and Visitors

❖ On TN Govt’s directive Ban on “use of one time use and throwaway plastics” following initiatives implemented progressively

❖ On 27/09/19 a knowledge sharing session on “Awareness on Harmful effects of plastic” was conducted by MR-H2 to the staffs of “Central Silk Board Authority of India”-Hosur

2727


❖ MR-EMS – conducted a Tech-Talk session on “ Energy Trends in Efficiency Improvements of Blowers” to the members of ISHRAE,Hosur chapter

❖ MR-EMS – conducted knowledge sharing session on “ Energy Conservation Practices” to the final year students of Adhiyamaan Engineering College,Hosur on 14th December’2019

2828

➢ During Lockdown we have extended our arm for social welfare

➢ From 1st April 20, we were providing 3 time meals to various category of people – Team at GH, Primary Health Centres, Stranded people, Migrated community, Police and Municipal workers till June’20

➢ Donated 1000 nos of N 95 MASKS to GH.

➢ Organized basic provision items, vegetables to interior village communities – covered about 09 villages and 03 homes – provided worth of Rs.2 lakhs of materials

➢ Provided nutrition food to 20 HIV infected persons.

➢ Distributed the HIV Tablets from ART Centre, GH, Hosur and Krishnagiri to 100 HIV infected patients, who could not come to GH – Due to no transportation.

➢ Distributed 200 packets of buttermilk to the working staff of different departments, on various points for about 15 days.


COVID Care beyond boundary…

2929

COVID – 19 Warriors: Screening Camp for Interstate Migrant Workmen

A free COVID 19 screening camp was arranged for the inter state migrantworkmen on 13th April 2020.

236 inter state migrant workmen were screened and none of them were foundwith any symptoms.

These migrants were working under different contracts in ALH2.

The screening comprises self evaluation of COVID 19 through a questionnaire,temperature monitoring, vitals assessment (oxygen saturation, pulse rate) andclinical examination


3030

COVID 19 – Care beyond Work (during Country wide lockdown)

Due to the outbreak of Covid-19, the entire nation is under lockdown, resulting in suspension of interstate transportation, closure of hotels / mess.

To support the Interstate migrant / Trainees, AL provides three times food for them till normalcy resorted, every day 300 breakfast/ lunch/ dinner are being distributed to Interstate migrant workmen


3131

H2 AWARDS TIMELINE

1994 Regular Production Commenced

2004 1. CII Excellence in Water Management Award2. CII Leadership & Excellence in SHE Award

2017 Sustainability Award

QMS Certification: ISO 9001 - 1995

1997 Stallion Vehicle rolled out for the Indian Army

Euro-4 Compliant CNG Engines -2009

2002 1. EMS Certification ISO 14001:19962. CII Leadership & Excellence in SHE Award

2006 CII Leadership & Excellence in SHE Award

2013 1.Green Manufacturing Excellence Award 2. BEE Energy Conservation Merit Award

SKD to Ordinance Factory – Indian Army - 1998

1. Euro-3 Compliant Vehicles introduced - 20052. CII-Leadership & Excellence in SHE Award

Deming Prize- 2017

2008 1.CII Excellence in Water Management Award2.CII Leadership & Excellence in SHE Award

2015 Green Company of the Year Award

2019 CII Energy Efficient Unit Award

1. Euro 2 complaint vehicles rolled out - 20032. CII Excellence in Energy Management Award

1.Golden Peacock – Env. Mgmt Award - 20072. CII-Leadership & Excellence in SHE Award

BEE - National Energy Conservation Award -2014

Birla Institute of Management Award on CSR - 2018

EMS certification ISO14001:2015 - 2019

Hinduja Group An Overview

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